_

CO-1

C0-1
COOLING SYSTEM
Page
CO-2

CO-3
TROUBLESHOOTING CHECK AND REPLACEMENT OF
ENGINE COOLANT WATER PUMP THERMOSTAT RADIATOR ..... ELECTRIC
COOLING FAN ..
CO-4
CO-6 CO-7

C0-12
CO
COOKING SYSTEM - Troubleshooting
CO

TROUBLESHOOTING
Problem
Possible cause
Remedy
Page
COOLING SYSTEM - Check and Replacement of Engine Coolant
CO-3 CHECK AND REPLACEMENT OF ENGINE
COOLANT 1. CHECK COOLANT LEVEL
The coolant level should be between the LOW and FULL lines. If low, check
for leakage and add coolant up to the FULL line.
Engine overheats
Adjust or replace belt Clean radiator or condenser
CH-4 CO-7

Repair as necessary
C00060
Fan belt loose or missing pirt, leaves or insects on radiator or
condenser Hoses, water pump, thermostat housing, radiator, heater, core plugs or head
gasket leakage Thermostat faulty Irojection timing retarded Electric cooling system
faulty Pediator hose plugged or rotted Water pump faulty Hadiator plugged or cap faulty
Cylinder head or block cracked or water passage clogged
CO-6 EM-20 CO-12
Check thermostat Set timing Inspect electric cooling system Replace hose
Replace water pump Check radiator and cap Repair as necessary
CHECK COOLANT QUALITY There should not be any excessive deposit of rust or
scales around the radiator acp or radiator filler hole, and the coolant should also be
free from oil. If excessively dirty, replace the coolant.
C0-4 CO-7

C00002
NOTE: If the engine tends to overheat, removal of the thermostat would have an adverse effect,
causing a lowering of cooling efficency.
FR Vehicles

Drain Cock
Drain Cock
3. REPLACE ENGINE COOLANT
(a) Drain the coolant from the radiator and engine drain
cocks. (Engine drain is at right rear of engine block.) (b) Close the drain cocks. (c) Fill the
system with coolant.
Use a good brand of ethylene-glycol base coolant,
mixed according to the manufacturer's directions. Coolant capacity (w/ heater):
CE70 6.3 liters
(6.7 USąts, 5.5 Imp.qts) CE80 7.3 liters
(7.7 USqts, 6.4 Imp.gts) CV, CT 7.5 liters
(7.9 USots, 6.6 Imp.gts) CM 7.0 liters
17.4 USqts, 6.2 Imp.gts) CR 7.1 liters
(7.5 USqts, 6.2 Imp.qts) (d) Start the engine and check for leaks. (e) Recheck
the coolant level and refill as necessary.
FF Vehicles

Drain Cock

Drain Cock
CO-4
COOLING SYSTEM
Water Pump
COOLING SYSTEM - Water Pump
CO-5

WATER PUMP
COMPONENTS
INSPECTION OF WATER PUMP 1. INSPECT WATER PUMP
PULLEY
Check that water pump pulley operation is not rough or noisy. If
neccessary, replace the water pump.
No. 2 Timing Belt Cover RH Engine Mounting
Water Pump Bracket (FF Vehicles)
Injection Pump Drive Pulley Gasket
Injection Pump
B6138

2.
INSPECT FAN BRACKET (FR Vehicles) Check that fan bracket operation is
not rough or noisy. If necessary, replace the fan bracket

B2053
Fan Bracket (FR Vehicles)
3.
nunc
INSPECT FLUID COUPLING (FR Vehicles) Check the fluid coupling for
damage and silicon oil leakage. If necessary, replace the fluid coupling.
con

No. 1 Timing Belt Cover Crankshaft Pulley

Timing Belt
82054
C00329

REMOVAL OF WATER PUMP

1. DRAIN COOLANT
Open the radiator and engine drain cocks, and allow the
coolant to drain into a suitable container 2. REMOVE INJECTION PUMP SET
NUTS 3. REMOVE NO. 3 TIMING BELT COVER

REMOVE WATER PUMP Removeseven bolts, and remove the water pump with
its gasket.

C00091

CO-6
COOLING SYSTEM - Water Pump. Thermostat
COOLING SYSTEM - Thermostat, Radiator
CO-7
INSTALLATION OF WATER PUMP (See page CO-4)
Water Inlet
Gasket
Jiggle Valve
INSTALLATION OF THERMOSTAT
PLACE THERMOSTAT IN CYLINDER BLOCK Install a new gasket to the
thermostat and set the ther mostat in the cylinder block with the jiggle valve on
top.

Bolt Length (mm)

1. INSTALL WATER PUMP OVER NEW GASKET
Install the water pump on a new gasket with seven bolts. Torque the bolts.
NOTE: Each bolt length (mm) is indicated in the figure.
Torque: 185 kg-cm (13 ft-lb, 18 Nim) 2. INSTALL NO.3 TIMING BELT
COVER 3. INSTALL INJECTION PUMP SET NUTS
REFILL WITH COOLANT (See step 3 on page CO-3) 5. START
ENGINE AND CHECK FOR LEAKS
Thermostat
CO0083
87055

2. INSTALL WATER INLET

Install the water intet with two bolts. Torque the bolts. Torque: 75 kg-cm (65 in.-Ib,
7.4 Nm)

REFILL WITH COOLANT (See step 3 on page CO-3) 4. START

ENGINE AND CHECK FOR LEAKS

87051

RADIATOR CLEANING OF RADIATOR

THERMOSTAT REMOVAL OF THERMOSTAT 1. DRAIN
COOLANT 2. REMOVE WATER INLET
Remove two bolts and water inlet from the cylinder block. 3. REMOVE
THERMOSTAT WITH GASKET
B7051

Radiator Tester
INSPECTION OF THERMOSTAT
NOTE: Thermostat is numbered with the valve opening temperature. (a) Immerse
the thermostat in water and heat the water
gradually
Using water or a steam cleaner, remove any mud and dirt from the radiator core.
CAUTION: If using a high pressure type cleaner, be careful not to deform the fins
of the radiator core. If the cleaner nozzle pressure is 30 - 35 kg/cm2 (427 - 498 psi,
2,942 – 3,432 kPa), keep a distance of at least 40 – 50 cm (15.75 = 19.69 in.) between the
radiator core and cleaner nozzle. INSPECTION OF RADIATOR 1. CHECK
RADIATOR CAP
Using a radiator tester, pump the tester until the relief valve opens. Check that the
valve opens between 0.75 kg/ cm (10.7 psi, 74 kPa) and 1.05 kg/cm (14.9 psi, 103 kPa).
Check that the pressure does not drop rapidly when pressure on the cap is
below 0.6 kg/cm2 (8.5 psi, 59 kPa). If either check is not within limits, replace the
cap. CHECK COOLING SYSTEM FOR LEAKS Attach radiator tester to the
radiator, and pump the tester to 0.9 kg/cm? (12.8 psi, 88 kPa). Check that pressure
does not drop. If the pressure drops, check for leaks from the hoses, radiator or
water pump. If no external leaks are found, check the heater core, block and head.
Radiator Cap

X 83
COD03

Hose
(b) Check the valve opening temperature and the valve
lift. Valve opening temperature: 80 - 84°C
(176 - 183°F) Valve lift: More than 8 mm (0.31 in.) at 95°C (203°F) If the valve
opening temperature and valve lift are not within the specifications above, replace
the thermostat, (c) Check that the valve spring is tight when the ther
mostat is fully closed. If not closed, replace the thermostat.
Radiator Tester
2

CO00821
83543
CO

COOLING SYSTEM - Radiator

COOLING SYSTEM - Radiator

(b) Pull the tank plates outward.

DISASSEMBLY OF RADIATOR (RESIN TANK
Only)
Tank Plate

-Upper Tank
@00086

-Tank Plate -O-Ring

2. REMOVE TANK AND O-RING
(a) Pull the tank upward. (b) Remove the O-ring.
Core Plates

- Tank

-O-Ring
Core Plate

Core
Core —
Core Subassembly

A/T Vehicles Only

Oil Cooler
Core Plate

Core Plate
-Core Plate -O-Ring - Tank Plate
Core

0 0 058
Lower Tank
ASSEMBLY OF RADIATOR (See page CO-8) 1. INSPECT CORE
PLATE
Inspect the core plate for damage NOTE:
• if the sides of the core plate groove are deformed, reassembly of the tank
will be impossible. Therefore, first correct any deformation with a pliers or
such. © Water leakage will result if the bottom of the core plate
groove is damaged or dented. Therefore, repair or re
place if so damaged. MEASURE HEIGHT AND SELECT SST PUNCH
(a) Measure the height of A, as shown, for the lower and
upper tanks.
CODO38 C00084
C00042

1. REMOVE TANK PLATE

(a) Raise the claws of the tank plates with SST in the
numerical order shown in the figure. SST 09230-00010 NOTE: Be careful not to
damage the core plate.
F

C00085
CO0087

Tank
HIGH

(b) Select a low punch SST. SST 09230-00010 NOTE: Use high punch if
height (A) is 6 mm (0.236 in.). (c) Install SST.
SST

Tank Plate

C00049 C00041
275631

CO-10
COOLING SYSTEM - Radiator
COOLING SYSTEESTEM - Radiator
CO-11
3. INSTALL NEW O-RING AND TANK
NOTE: (1) Clean the tenk and core plate.
NOTENOTE:
(1) 91) Stake with just enough pressure to leave a mark on
# the claw. The staked plate height (B) should be as
f follows: HeigHeight (B): 9.0 - 9.4 mm (0.354 - 0.370 in.)

BBBBBBBB
85441
836421

(2) Inspect the O-ring for twists.

(2)
Pipe
EL) Do not stake the areas protruding around the pipes,
brackets or tank ribs,

Claw
-O-Ring

27555
83641

(3)
LLLLLL

INSTALL TANK PLATES Insert the tank plates from both ends in the
direction of the arrows. Firmly set the tank plates in the core plate,
NOTE: The upper and lower tank plates are not the same so be careful
not to interchange them.
Tet) The points shown in the illustration cannot be staked
with the SST. Use a pliers or such and be careful not
to damage the core plates.

900g
COX088
C00089

5. STAKE CLAW OF TANK PLATES

Stake the claws of the tank plates with SST in the numeri cal order shown
in the figure. SST 09230-00010
6. INSPILSPECT FOR WATER LEAKS
(a) Tighten the drain plug. (b) Bo) Plug the inlet and outlet pipes of the
radiator with
9 SST. SST ST 09230-00010 fc) - Using a radiator tester, apply
pressure to the radiator. Test mest pressure: 1.8 kg/cma (26 psi, 177
kPa)

co00e5
27557 27558

Tank Plate Punch

CAUTION: If the bottom of the core plate is staked with the SST on the
guide block stopper, it may result in water leakage.
-Tank
Tank
oa

(d) IH) Inspect for water leaks: NOTE OTE: On radiators with resin tanks,
there is a clearance betweetween the core plate and tank plate where a minute
amourmount of air will remain, causing an appearance of an air leak v tak when
the radiator is submerged in water. Therefore, beformefore performing the
water leak test, first swish the radiatodiator around in the water until all
air bubbles disappear.
Core Plate Tank Plate
Clearance
VU

7.
Stopper Guide Block
-O-Ring
co0035
PAINILAINT TANK PLATES NO TE OTE: If the water leak test checks
out okay, allow the radiatediator to completely dry and then paint the
tank plate.
C00043 C00046

C0-12
COOLING SYSTEM - Electric Cooling Fan
COOLING SYSTEM - Electric Cooling Fan
CO-13
ELECTRIC COOLING FAN SYSTEM CIRCUIT
Ex. CV with A/T
ON-VEHICLE INSPECTION Low Temperature (below 83°C or
181°F] 1. TURN STARTER SWITCH ON
Confirm that the fan stops. If it does not, check the fan relay and temperature
switch, and check for a separated connector or severed wire be tween the relay and
temperature switch.
Starter Switch
IGN Fuse 7.5A

Fusible Link
33847 83648

Fusible Link
Engine Main Relay
Cooling Fan Motor Relay
DISCONNECT TEMPERATURE SWITCH CONNECTOR Confirm that the fan turns. If
not, check the fan relay, fan motor, main relay and fuse, and check for a short circuit
between the fan relay and
temperature switch. 3. CONNECT TEMPERATURE SWITCH CONNECTOR
Battery
Cooling Fan Motor
Temp. Switch
B7057 33650

90°c
High Temperature (above 90°C or 194°F) 4. START ENGINE
(a) Raise the engine temperature to above 90°C (194°F). (b) Confirm that the
fan turns. If not, replace the temperature switch.
CV with A/T only
Fusible Link
C00090

Starter Switch
No. 2 Cooling Fan Motor
Condensor

Fuse 7.58
Fuse 7.5A
Fusible Link

INSPECTION OF ELECTRIC COOLING FAN 1. INSPECT

TEMPERATURE SWITCH
LOCATION: On the radiator. (a) Using an ohmmeter, check that there is no continuity
when the coolant temperature is above 90°C (194°F).
Above 90°C VA
Engine Main Relay
Cooling Fan
Motor Relay

Battery
Cooling Fan Motor
No. 2 Cooling Fan Motor Relay
Temp Switch
(b) Check that there is continuity when the coolant tem
perature is below 83°C (181°F). If continuity is not as specified, replace the switch.
Below 83°CV
CO-14
COOLING SYSTEM - Electric Cooling Fan

2. INSPECT COOLING FAN MOTER RELAY

LOCATION: In the engine compartment relay box. (a) Using an
ohmmeter, check that there is continuity
between terminals 1 and 2. (b) Check that there is continuity between
terminals 3
and 4. If there is no continuity, replace the relay.
(c) Apply battery voltage between terminals 1 and 2. (d) Check that
there is no continuity between terminals 3
and 4. If there is continuity, replace the relay.

Continuity
3. INSPECT NO. 2 COOLING FAN MOTOR RELAY
ICV with A/T only) LOCATION: In the engine compartment relay box.
(a) Using an ohmmeter, check that there is continuity
between terminals 1 and 3. (b) Check that there is no continuity between
terminals 1
and 4. If continuity is not as specified, replace the relay.
tout

No Continuity
BE0012

(c) Apply battery voltage between, terminals 6 and 2. (d)

Check that there is continuity between terminals 1
4. INSPECT
and 4. If there is no continuity, replace the relay.

ENGINE MAIN RELAY (See page CH-19)

Continuity
B0001
BE00101

5. INSPECT FAN MOTOR

(a) Connect battery voltage to the fan motor connector. (b) Check
to see that the motor rotates smoothly.

83654